Modular pilot assembly with self-contained stripper and method for metal forming dies

ABSTRACT

A pilot assembly and method has a cylindrical pilot body with a tapered outer end, a grooved inner end, and a central portion with at least one inwardly curved side wall relief, as well as internally mounted reciprocating ejector pins with outer ends that protrude through holes in the outer body end to strip stock from the pilot. A spring has its outer end mounted in the groove in the outer body end, and an inner end attached to the inner body end in a pre-tensed condition. A cap screw has an enlarged head that has at least a portion thereof fit into the pilot sidewall relief, and a threaded shank that anchors the pilot in an associated die member.

CROSS REFERENCE TO RELATED APPLICATIONS AND CLAIM TO PRIORITY

The present application is a continuation of and claims priority under35 U.S.C. § 120 to commonly assigned U.S. Pat. No. 9,895,740, issuedFeb. 20, 2018, entitled MODULAR POILOT ASSEMBLY WITH SELF-CONTAINEDSTRIPPER AND METHOD FOR METAL FORMING DIES, which claims the priorityunder 35 U.S.C. § 120 to U.S. Pat. No. 9,138,799, issued Sep. 22, 2015,entitled MODULAR PILOT ASSEMBLY WITH SELF-CONTAINED STRIPPER AND METHODFOR METAL FORMING DIES, which claims the priority benefit under 35U.S.C. § 119 to U.S. provisional patent application No. 61/547,785,filed Oct. 17, 2011, entitled PILOT ASSEMBLY AND METHOD FOR METALFORMING DIES AND THE LIKE, both of which are incorporated herein byreference, as well as U.S. Pat. No. 9,289,815, issued Mar. 22, 2016,entitled MODULAR PILOT ASSEMBLY WITH SELF-CONTAINED STRIPPER AND METHODFOR METAL FORMING DIES, which is also incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to metal forming dies and the like, and inparticular to a modular pilot assembly with self-contained stripper andassociated method.

Metal forming dies, such as stamping dies and the like, are well knownin the art.

Progressive metal forming dies are unique, very sophisticated mechanismswhich have multiple stations or progressions that are alignedlongitudinally, and are designed to perform a specified operation ateach station in a predetermined sequence to create a finished metalpart. Progressive stamping dies are capable of forming complex metalparts at very high speeds, so as to minimize manufacturing costs.

Heretofore, the dies used in metal forming processes have typically beenindividually designed, one of a kind assemblies for a particular part,with each of the various components being handcrafted and custom mountedor fitted in an associated die set, which is in turn positioned in astamping press. Not only are the punches and the other forming tools inthe die set individually designed and constructed, but the other partsof the die set, such as stock lifters, guides, end caps and keepers, camreturns, pilots, etc. are also custom designed, and installed in the dieset. Current die making processes require carefully machined, precisionholes and recesses in the die set for mounting the individualcomponents, such that the same are quite labor intensive, and requiresubstantial lead time to make, test and set up in a stamping press.Consequently, such metal forming dies are very expensive to design,manufacture, and repair or modify.

Pilot assemblies, such as that disclosed in U.S. Pat. No. 4,342,214, areused for locating a work piece in successive forming stages of amachine, such as a punch press, where the work piece is progressivelymoved through the forming stages of the machine. The pilot assemblytypically includes a pilot pin mounted to a movable die member of themachine for guiding entry into a previously formed hole in a work pieceor in a companion die member as the die members are moved toward eachother.

FIGS. 5-8 illustrate several well-known prior art metal forming dies andassociated pilot mechanisms, which further represent the background ofthe present invention. For example, FIG. 5 illustrates one half of a dieset 100, which includes a first die member 101 having a plurality oflongitudinally spaced apart work stations 102 at which various bending,forming, cut-off and/or punching operations are performed on an elongatestrip of metal stock 103. As best illustrated in FIG. 6, the prior artpilot mechanism 104 for the illustrated die set 100 includes a piercetool punch 105 located at an upstream portion of stock strip 103, which,in the illustrated example, forms a vertically oriented through hole 106in the stock strip 103 at regularly spaced apart intervals along thestock strip. The through holes or pilot holes 106 are selectivelyengaged by a series of pilot pins 107 positioned on at least selectedones of the die work stations 102, which serve to precisely locate thestock strip 103 in the work stations, and retain the same in placeduring the metal forming stroke of the die tools. After each metalforming stroke of the die tools, the pilot pins 107 are retracted out oftheir associated pilot holes 106 in the stock strip 103, and the stockstrip is then shifted longitudinally to the next adjacent work station102, until the metal part has been completely formed and cut off of thestock strip. When the pilot pins 107 are retracted out of the pilotholes 106 in the stock strip 103, the stock strip tends to stick on oneor more of the pilot pins, thereby requiring some type of strippermechanism to separate them, such that the stock strip can be quickly andsequentially advanced longitudinally through the various die stations.

FIG. 7 illustrates another known prior art pilot assembly that includesa rectangularly shaped block or base 111 that is mounted in a blind holepocket 112 in an associated upper die member 113. The base block 111includes a central aperture 114 in which a pilot pin 115 is retained,and two laterally offset reaction apertures 116 in which a pair ofstripper assemblies are received and retained. A female punch tool 117is positioned in the lower die member 122, and closely receives thepilot pin 115 to precisely locate the stock strip 5 in the associatedwork station 112. Each of the stripper assemblies comprises a plungershaped rod 118 having an outer end 119 protruding outwardly from baseblock 111 toward the stock strip 103, and an inner end 120 with a coilspring 121 received thereover which resiliently urges the rods 118outwardly on opposite sides of pilot pin 15, and serve to strip thestock strip 103 from the exterior surface of the pilot pin 115 as thepilot pin and associated upper die member 113 are raised to a divergedcondition relative to the lower die member 122.

FIG. 8 illustrates yet another known prior art pilot assembly, whichincludes an enlarged, flat mounting plate 126 which attaches to theupper surface 127 of the upper die member 113 using a pair of cap headscrews 128 having threaded shanks 129 that are anchored in the upper diemember 113. The upper die member 113 includes a central aperture 114 inwhich a pilot pin 115 is received and retained, along with a pair ofreaction apertures 116 disposed on opposite sides of pilot pin 115, eachof which receives and retains therein a plunger shaped rod 118. Theouter ends 119 of the rods 118 protrude outwardly from the lower surfaceof upper die member 113, while the inner ends 120 of rods 118 have coilsprings 121 received thereon which resiliently urge rods 118 outwardly,such that the outer ends 119 of rods 118 serve to strip the stock strip5 away from the exterior surface of the pilot pin 115, and therebypermit the stock strip 5 to be shifted longitudinally into the nextadjacent work station.

While such prior pilot assemblies have proven generally successful, theyare rather expensive and time consuming to construct and install in anassociated die set, such that further improvements and enhancements tothe same, as well as metal forming dies generally, would be clearlyadvantageous, and are disclosed herein.

SUMMARY OF THE INVENTION

One aspect of the present invention is a multi-station progressive metalforming die having at least two mutually converging and diverging diemembers between which an elongate stock strip is shifted longitudinallyto form parts from the stock strip, the improvement of a modular pilotassembly with self-contained stripper, comprising:

a pilot operably supported on one of the die members and having an outerend oriented toward the stock strip, an oppositely disposed inner endoriented away from the stock strip, and a medial portion disposedaxially between the outer and inner ends, and including:

a generally cylindrically shaped body portion disposed at the medialportion of the pilot, having a generally closed outer end orientedtoward the stock strip, a generally open inner end oriented away fromthe stock strip, and an outer sidewall with a least one fastener relieftherein having an arcuately shaped, radially inwardly curved reliefsidewall that extends from the closed outer end to a generally flatarcuately shaped relief end surface facing toward the stock strip andspaced axially a predetermined distance from the open inner end, as wellas at least one axially extending ejector pin aperture which opensthrough the closed outer end and into the open inner end;

a generally tapered point portion disposed at the outer end of thepilot, having a circularly shaped innermost collar portion disposedadjacent the closed outer end of the body portion shaped for closereception in a pilot hole in the stock strip, and a generallyfrusto-conically shaped outer portion configured to engage the pilothole in the stock strip and guide the same to a predetermined positionin an associated die forming station;

a generally cylindrically shaped spring retainer rod portion disposed atthe inner end of the pilot, having an outer end oriented toward thestock strip, an inner end oriented away from the stock strip, and anouter sidewall with a diameter that is less than the diameter of theouter sidewall of the body portion, thereby forming an annularly shapedspring groove adjacent the outer end of the spring retainer rod portion,as well as a retainer groove disposed adjacent the inner end of thespring retainer rod portion;

a spring member having a generally hollow interior that is received ontoand over the spring retainer rod portion of the pilot, an outer endoriented toward the stock strip and received in the spring groove, andan opposite inner end oriented away from the stock strip and positionedadjacent to the retainer groove in the spring retainer rod portion;

at least one rigid ejector pin slidingly received and retained in theejector pin aperture in the body portion, having an outer end thatprotrudes outwardly from the closed outer end of the body portion whenurged to an extended condition to contact the stock strip and strip thesame away from the pilot, and retracts toward the body portion whenurged to a retracted position, and an inner end that operably engagesthe outer end of the spring member and is thereby biased outwardly bythe spring member toward the extended condition;

a retainer ring detachably received in the retainer groove in the springretainer rod portion and engaging the inner end of the spring member ina pre-tensed condition to bias the ejector pin toward the extendedcondition; and

a mounting screw having an enlarged head portion with a circular planshape that is at least partially, closely received in the fastenerrelief in the body portion, an annularly shaped inner face oriented awayfrom the stock strip and abuttingly engaging the relief end surface ofthe fastener relief in the body portion, and a threaded shank portionanchored in the one die member to securely, yet detachably mount thepilot assembly on the one die member in a manner which causes theejector pin to automatically reciprocate between the retracted andextended positions relative to the body portion of the pilot duringoperation of the metal forming die to insure that the stock strip isconsistently stripped away from the pilot.

Yet another aspect of the present invention is a A modular pilotassembly with self-contained stripper for multi-station progressivemetal forming dies having at least two mutually converging and divergingdie members between which an elongate stock strip is shiftedlongitudinally to form parts from the stock strip, comprising:

a pilot configured for operable support on an associated die member, andhaving an outer end oriented toward the stock strip, an oppositelydisposed inner end oriented away from the stock strip, and a medialportion disposed axially between the outer and inner ends, andincluding:

a generally cylindrically shaped body portion disposed at the medialportion of the pilot, having a generally closed outer end orientedtoward the stock strip, a generally open inner end oriented away fromthe stock strip, and an outer sidewall with a least one fastener relieftherein having an arcuately shaped, radially inwardly curved reliefsidewall that extends from the closed outer end to a generally flat,arcuately shaped relief end surface facing toward the stock strip andspaced axially a predetermined distance from the open inner end, as wellas at least one axially extending ejector pin aperture which opensthrough the closed outer end and into the open inner end;

a generally tapered point portion disposed at the outer end of thepilot, having a circularly shaped innermost collar portion disposedadjacent the closed outer end of the body portion, shaped for closereception in a pilot hole in the stock strip, and a generallyfrusto-conically shaped outer portion configured to engage the pilothole in the stock strip and guide the same to a predetermined positionin an associated die forming station;

a generally cylindrically shaped spring retainer rod portion disposed atthe inner end of the pilot, having an outer end oriented toward thestock strip, an inner end oriented away from the stock strip, and anouter sidewall with a diameter that is less than the diameter of theouter sidewall of the body portion, thereby forming an annularly shapedspring groove adjacent the outer end of the spring retainer rod portion,and including a retainer groove disposed adjacent the inner end of thespring retainer rod portion;

a spring member having a generally hollow interior received on and overthe spring retainer rod portion of the pilot, an outer end orientedtoward the stock strip and received in the spring groove, and anopposite inner end oriented away from the stock strip and positionedadjacent to the retainer groove in the spring retainer rod portion;

at least one rigid ejector pin slidingly received and retained in theejector pin aperture in the body portion, having an outer end thatprotrudes outwardly from the closed outer end of the body portion whenurged to an extended condition to abut the stock strip and strip thesame away from the pilot, and retracts toward the body portion whenurged to a retracted position, and an inner end that operably engagesthe outer end of the spring member and is thereby biased outwardly bythe spring member toward the extended condition;

a retainer ring detachably received in the retainer groove in the springretainer rod portion and engaging the inner end of the spring member ina pre-tensed condition to bias the ejector pin toward the extendedcondition; and

a mounting screw having an enlarged head portion with a circular planshape that is at least partially, closely received in the fastenerrelief in the body portion, an annularly shaped inner face oriented awayfrom the stock strip and abuttingly engaging the relief end surface ofthe fastener relief in the body portion, and a threaded shank portionconfigured for anchoring in an associated die member to securely, yetdetachably mount the pilot assembly on the associated die member in amanner which causes the ejector pin to automatically reciprocate betweenthe retracted and extended positions relative to the body portion of thepilot during operation of the metal forming die to insure that the stockstrip is consistently stripped away from the pilot.

Yet another aspect of the present invention is a method for making amulti-station progressive metal forming die having at least two mutuallyconverging and diverging die members between which an elongate stockstrip is shifted longitudinally to form parts from the stock strip, withthe improvement of at least one modular pilot with self-containedstripper for precisely locating the stock strip in the die stations,comprising:

forming a generally cylindrically shaped body portion on a medialportion of the pilot with a generally closed outer end oriented towardthe stock strip, a generally open inner end oriented away from the stockstrip, and an outer sidewall with a least one fastener relief thereinhaving an arcuately shaped, radially inwardly curved relief sidewallthat extends from the closed outer end to a generally flat, arcuatelyshaped relief end surface facing toward the stock strip and spacedaxially a predetermined distance from the open inner end, as well as atleast one axially extending ejector pin aperture which opens through theclosed outer end and into the open inner end;

forming a generally tapered point portion on an outer end of the pilotwith a circularly shaped innermost collar portion disposed adjacent theclosed outer end of the body portion shaped for close reception in apilot hole in the stock strip, and a generally frusto-conically shapedouter portion configured to engage the pilot hole in the stock strip andguide the same to a predetermined position in an associated die formingstation;

forming a generally cylindrically shaped spring retainer rod portion onan inner end of the pilot with an outer end oriented toward the stockstrip, an inner end oriented away from the stock strip, and an outersidewall with a diameter that is less than the diameter of the outersidewall of the body portion, thereby forming an annularly shaped springgroove adjacent the outer end of the spring retainer rod portion, aswell as a retainer groove disposed adjacent the inner end of the springretainer rod portion;

forming at least one rigid ejector pin with an inner end, and an outerend configured to protrude outwardly from the closed outer end of thebody portion when urged to an extended position to contact the stockstrip, and to retract toward the body portion when urged to a retractedposition;

inserting the ejector pin into the ejector pin aperture in the bodyportion of the pilot, such that the ejector pin is slidingly receivedand retained in the ejector pin aperture for longitudinal reciprocationtherein between the extended and retracted positions;

selecting a spring member with a generally hollow interior, an outer endoriented toward the stock strip, and an opposite inner end oriented awayfrom the stock strip;

positioning the hollow interior of the spring member onto and over thespring retainer rod portion of the pilot, with the outer end of thespring member received in the spring groove and abutting the inner endof the ejector pin, and the inner end of the spring member positionedadjacent to the retainer groove in the spring retainer rod portion;

shifting the inner end of the spring member outwardly along the springretainer rod portion of the pilot to compress the spring member to apre-tensed condition, such that the outer end of the spring memberoperably engages the inner end of the ejector pin and biases the ejectorpin to the extended position;

installing a retainer ring in the retainer groove in the spring retainerrod portion with the spring member in the pre-tensed condition, suchthat the retainer ring abuttingly engages the inner end of the springmember and retains the spring member in the pre-tensed condition on thespring retainer rod portion of the pilot, thereby resiliently urging theejector pin to the normally extended position;

forming a non-threaded pilot aperture in a mounting face of one of thedie members with a shape to closely receive and retain the body portionof the pilot therein;

forming a threaded mounting screw aperture in the mounting face of theone die member at a location spaced laterally apart from the pilotaperture a predetermined distance;

inserting the pilot into the pilot aperture in the one die member withthe outer sidewall of the body portion of the pilot closely receivedtherein, and with the fastener relief in the body portion of the pilotfacing and aligned with the mounting screw aperture in the one diemember, so as to accurately locate the pilot on the one die member;

selecting a mounting screw having an enlarged head portion with acircular plan shape sized for at least a portion thereof to be closelyreceived in the fastener relief in the body portion of the pilot, anannularly shaped inner face sized for abutting engagement with at leasta portion of the relief end surface of the fastener relief in the bodyportion of the pilot, and a threaded shank portion;

inserting the threaded shank portion of the mounting screw axially intothe mounting screw aperture in the mounting face of the one die member,such that at least a portion of the enlarged head portion of themounting screw is closely received in the fastener relief and adjacentthe relief sidewall on the body portion of the pilot; and

tightening the mounting screw in the mounting screw aperture in the onedie member, thereby abuttingly engaging at least a portion of the innerface of the mounting screw head portion securely against the relief endsurface of the fastener relief in the body portion of the pilot tosecurely, yet detachably mount the pilot assembly on the one die memberin a manner which causes the ejector pin to automatically reciprocatebetween the retracted and extended positions relative to the bodyportion of the pilot during operation of the metal forming die to insurethat the stock strip is consistently stripped away from the pilot.

Yet another aspect of the present invention is a pilot assembly that canbe easily installed in an associated die member by simple machining asingle pocket and a single tapped retainer hole therein. The pilotassembly has a self-contained stripper with no loose parts or pieces, isconstructed from fewer components than prior art pilot devices, andpositively prevents the stock strip from sticking to the pilot. Thepilot body itself provides the precise location of the stripper assemblyin an associated die pad at a location close to the stock strip. Thestripper assembly has a modular design that can be economicallymanufactured, a small profile and footprint, and can be easily assembledand disassembled from an associated die member. Due to the design of thepilot assembly, the ejector pins can be located in close proximity tothe pilot pin, so as to positively and dependably, repeatedly strip thestock strip from the pilot pin. The pilot assembly has a single screwmounting system for quick and easy installation in an associated diemember. The pilot can be machined from a single piece of solid materialin one setup to achieve tighter tolerances and better concentricitybetween the pilot body and the pilot point, as well as reducedmanufacturing costs. The pilot assembly is efficient in use, economicalto manufacture, capable of a long operating life, and particularly welladapted for the proposed use.

These and other advantages of the invention will be further understoodand appreciated by those skilled in the art by reference to thefollowing written specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a modular pilot assembly withself-contained stripper embodying the present invention, shown installedin a die set carrying a stock strip in which pilot holes have beenformed.

FIG. 2 is an exploded perspective view of the pilot assembly shown inFIG. 1.

FIG. 3 is a perspective view of a portion of the pilot assembly in anassembled condition, taken from an outer end thereof.

FIG. 3A is a vertical cross-sectional view of the portion of the pilotassembly shown in

FIG. 3.

FIG. 4 is a top plan view of the pilot assembly.

FIG. 5 is a partially schematic perspective view of a representative,prior art die member shown in an open condition with a stock strippositioned along the various work stations of the die member.

FIG. 6 is a partially schematic cross-sectional view of a prior artpilot assembly.

FIG. 7 is a partially schematic cross-sectional view of another priorart pilot assembly.

FIG. 8 is a partially schematic cross-sectional view of yet anotherprior art pilot assembly.

FIG. 9 is a cross-sectional view of the pilot assembly embodying thepresent invention, shown installed in a die set.

FIG. 10 is a perspective view of a pilot portion of the pilot assembly,taken from an inner end thereof.

FIG. 11 is a perspective view of the pilot, taken from an outer endthereof.

FIG. 12 is a plan view of the inner end of the pilot.

FIG. 13 is a plan view of the outer end of the pilot.

FIG. 14 is a vertical cross-sectional view of the pilot.

FIG. 15 is a top plan view of an ejector pin portion of the pilotassembly.

FIG. 16 is a side elevational view of the ejector pin.

FIG. 17 is a bottom plan view of the ejector pin.

FIG. 18 is a top plan view of a mounting screw portion of the pilotassembly.

FIG. 19 is a side elevational view of the mounting screw.

FIG. 20 is a bottom plan view of the mounting screw.

FIG. 21 is a top plan view of a lock washer portion of the pilotassembly.

FIG. 22 is a vertical cross-sectional view of the lock washer.

FIG. 23 is a bottom plan view of the lock washer.

FIG. 24 is a side elevational view of the pilot shown mounted in a diemember, wherein the outer end of the pilot is partially inserted intothe pilot aperture of an associated stock strip.

FIG. 25 is a side elevational view of the pilot shown mounted in a diemember, wherein the outer end of the pilot is fully inserted into thepilot aperture in the stock strip.

FIG. 26 is a side elevational view of the pilot assembly shown mountedin a die member, wherein the pilot and upper die member have beendiverged from the stock strip and the lower die member.

FIG. 27 is a plan view of an upper pressure pad portion of the dieoriented with the normally lower mounting face oriented upwardly forillustration purposes, that has been machined for installation of thepilot assembly therein.

FIG. 28 is a perspective, cross-sectional view of the die member of FIG.27, taken along the line XXVIII-XXVIII.

FIG. 29 is an exploded, perspective view of the pilot assembly prior toinstallation into the normally lower mounting face of the machined upperdie pressure pad of FIGS. 27 and 28.

FIG. 30 is an exploded, perspective view of the pilot installed in thenormally lower mounting face of the upper pressure pad die member ofFIGS. 27-29, with the mounting screw and lock washer shown uninstalled.

FIG. 31 is a perspective view of the pilot assembly shown completelyinstalled in the normally lower mounting face of the upper pressure paddie member of FIGS. 27-30.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal” and derivativesthereof shall relate to the invention as oriented in FIGS. 1, 2 and 3A.However, it is to be understood that the invention may assume variousalternative orientations and step sequences, except where expresslyspecified to the contrary. It is also to be understood that the specificdevices and processes illustrated in the attached drawings, anddescribed in the following specification, are simply exemplaryembodiments of the inventive concepts defined in the appended claims.Hence, specific dimensions and other physical characteristics relatingto the embodiments disclosed herein are not to be considered aslimiting, unless the claims expressly state otherwise.

The reference numeral 1 (FIGS. 1-4) generally designates a modular pilotassembly with self-contained stripper embodying the present invention.As shown in FIG. 1, the pilot assembly 1 is particularly adapted for usein conjunction with a multi-station progressive metal forming die 2having at least two mutually converging and diverging die members 3 and4 between which an elongate stock strip 5 is shifted longitudinally toform parts from the stock strip. The pilot assembly 1 includes a pilot10 configured for operable support on one of the two die members 3, 4having an outer end 11 oriented toward the stock strip 5, an oppositelydisposed inner end 12 oriented away from the stock strip 5, and a medialportion 13 disposed axially between the outer and inner ends 11, 12. Agenerally cylindrically shaped body portion 15 is disposed at the medialportion 13 of pilot 10, and has a generally closed outer end 16 orientedtoward the stock strip 5, a generally open inner end 17 oriented awayfrom the stock strip 5, and an outer sidewall 18 with at least onefastener relief 19 that has an arcuately shaped, radially inwardlycurved relief sidewall 20 that extends from the closed outer end 16 to agenerally flat, arcuately shaped relief end surface 21 facing toward thestock strip 5 and spaced axially a predetermined distance from the openinner end 17. The body portion 15 also has at least one axiallyextending ejector pin aperture 22 which opens through the closed outerend 16 and into the open inner end 17. The pilot 10 also has a generallytapered point portion 24 at the outer end 11 of the pilot 10, having acircularly shaped innermost collar portion 25 disposed adjacent theclosed outer end 16 of body portion 15 that is shaped for closereception in a pilot hole 6 in the stock strip 5, and a generallyfrusto-conically shaped outer portion or nose 26 configured to engagethe pilot hole 6 in the stock strip 5 and guide the same to apredetermined position in an associated die forming station 12 of metalforming die 2. Pilot 10 also has a cylindrically shaped spring retainerrod portion 28 disposed at the inner end 12 of the pilot 10, having anouter end 29 oriented toward the stock strip 5, an inner end 30 orientedaway from the stock strip 5, and an outer sidewall 31 with a diameterthat is less than the diameter of the outer sidewall 18 of the bodyportion 15, thereby forming an annularly shaped spring groove 32 (FIGS.1 and 3A) adjacent the outer end 29 of spring retainer rod portion 28,as well as a retainer groove 33 positioned adjacent the inner end 30 ofthe spring retainer rod portion. Pilot assembly 1 also includes a springmember 35 having a generally hollow interior 36 received on and over thespring retainer rod portion 28 of the pilot 10, an outer end 37 orientedtoward stock strip 5 and received in the spring groove 32, and anopposite inner end 38 oriented away from the stock strip 5 andpositioned adjacent to the retainer groove 33 in the spring retainer rodportion 28, when in at least a partially assembled condition. The pilotassembly 1 also includes at least one rigid ejector pin 42 slidinglyreceived and retained in the ejector pin aperture 22 in the body portion15 of the pilot 10, and having an outer end 43 that protrudes outwardlyfrom the closed outer end 16 of body portion 15 when urged to anextended condition, as shown in FIGS. 3 and 3A, to abut the stock strip5 and strip the same from the pilot 10, and retracts toward the bodyportion 15 when urged to a retracted position, as shown in FIG. 25, andan inner end 44 that operably engages the outer end 37 of spring member38 and is thereby biased outwardly by the spring member 35 toward theextended condition. The pilot assembly 1 also includes a retainer ring47 detachably received in the retainer groove 33 in the spring retainerrod portion 28 and engaging the inner end 38 of the spring member 35 ina pre-tensed condition to bias the ejector pin 42 toward the extendedcondition. The pilot assembly also includes a mounting screw 50 havingan enlarged head portion 51 with a circular plan shape that is at leastpartially, closely received in the fastener relief 19 in the bodyportion 15 of the pilot 10, an annularly shaped inner face 52 orientedaway from the stock strip 5 and abuttingly engaging the relief endsurface 21 of the fastener relief 19 in the body portion 15 of pilot 10,and a threaded shank portion 53 configured for anchoring in anassociated die member 3, 4 to securely, yet detachably mount the pilotassembly 1 on the associated die member in a manner which causes theejector pin 42 to automatically reciprocate between the retracted andextended positions relative to the body portion 15 of the pilot 10during operation of the metal forming die to ensure that the stock strip5 is consistently and fully stripped away from the pilot 10.

The term “die member,” as used herein, refers to any portion of a metalforming die or die set, including, but not limited to, an upper diemember or die shoe, a lower die member, and all other die components,whether stationary or reciprocating, including a reciprocating pressurepad, or the like. In the illustrated examples, the pilot assembly 1 isshown mounted in a reciprocating upper die pad 3 located above a lowerstationary die shoe 4. However, as will be appreciated by those skilledin the art, pilot assembly 1 can be mounted in other types of diemembers and/or components in a variety of different positions andorientations, as necessary to precisely locate the stock strip 5 in thevarious workstations 102 of a metal forming die 100.

The illustrated pilot 10 (FIGS. 10-14) has a one-piece constructionformed from a solid bar of rigid material, such as metal or the like. Inthe illustrated pilot 10, the point portion 24 of pilot 10 is locatedconcentric with body portion 15 and spring retainer rod portion 28.Furthermore, the body portion 15 of the pilot 10 includes a plurality offastener reliefs 19 having a substantially identical configuration andarranged in a circumferentially spaced apart pattern around the outersidewall 18 of the body portion 15 of pilot 10 to facilitate mountingthe pilot assembly 1 at various locations and orientations on one ormore of the die members 3, 4. As best illustrated in FIG. 4, theillustrated body portion 15 of pilot 10 includes three fastener reliefs19, two of which are disposed generally diametrically opposite oneanother, and the third of which is oriented at an angle of approximately30°-40° from the fastener relief in which the mounting screw 50 isreceived in the illustration of FIG. 4.

Since the illustrated pilot 10 (FIGS. 10-14) has a one-piececonstruction formed from a solid bar of rigid material, such as metal orthe like, preferably, all machining operations on the solid bar of rigidmaterial are made during a single machine set-up, so as to achievegreater accuracy and consistency of the pilot 10, as well as reducedmanufacturing costs. The body portion 15 of the illustrated pilot 10 hasa plurality of ejector pin apertures 22 having a substantially identicalconfiguration and arranged in a circumferentially spaced apart, mutuallyparallel, axially extending pattern through the body portion 15 toensure effective and consistent stripping of the stock strip 5 from thepilot 10. As best shown in FIGS. 4, 12 and 13, the illustrated pilot 10includes four ejector pin apertures 22 which are spaced opposite fromone another on the closed outer end 16 of pilot body portion 15, and areradially positioned close to the collar portion 25 of pilot 10, so as toimprove the stripping action of the same. The illustrated pilot 10 alsoincludes four substantially identical ejector pins 42 which areslidingly received and retained for reciprocation in the ejector pinapertures 22 of body portion 15. As best illustrated in FIGS. 15-17, theouter ends 43 of ejector pins 42 have a size and shape similar to theelongate body portions of ejector pins 42, each with a flat circularplan configuration best suited for abuttingly engaging the strip stock5, while the inner ends 44 of ejector pins 42 are enlarged relative tothe size of the elongate body portions of ejector pins 42, and definecylindrically shaped, enlarged heads, each with a generally circular,flat inner face which facilitates engagement with the outer end 37 ofspring member 35. With reference to FIGS. 4 and 14, the body portion 15of the illustrated pilot 10 includes a threaded blind installationaperture 65 which extends axially into the closed outer end 16 of thebody portion 15 of pilot 10 at a location spaced radially outwardly fromand circumferentially inbetween the ejector pin apertures 22. A pullertool 66, shown schematically in FIG. 31, is configured for threadedengagement in the blind installation aperture 65 in pilot body portion15 to facilitate removal of the assembled pilot 10 from the associateddie member 3, 4, as discussed in greater detail below. Installationaperture 65 is disposed generally opposite the three fastener reliefs 19in pilot 1, as best shown in FIG. 4.

The illustrated spring member 35 comprises a conventional closed coilspring, which may have partially flattened ground ends 37, 38 to moresecurely abut the inner ends 44 of ejector pins 42, as well as theretainer ring 47 mounted in the retainer groove 33 at the inner end 30of spring retainer rod portion 28. The illustrated retainer ring 47comprises a conventional snap ring that is securely, yet detachablyreceived and retained in retainer ring groove 33.

With reference to FIGS. 18-20, the illustrated mounting screw 50comprises a conventional socket head cap screw having a tool engagingsocket 68 in the outer face 54 of the head portion 51 of mounting screw50, opposite inner face 52, and the threaded shank portion 53 includes aself-locking nylon patch 69, which prevents mounting screw 50 frominadvertently loosening from its tightened condition in the die member3, 4.

In the illustrated example, a lock washer 71 (FIGS. 21-23) is positionedover the threaded shank portion 53 of mounting screw 50, and furtherensures that the mounting screw 50 will not become inadvertentlyloosened during operation of the metal forming die. The illustrated lockwasher 71 is a conventional split, high-collar washer having a generallyannular plan configuration with an outer face 72 abuttingly engaging theinner face 52 of the head portion 51 of mounting screw 50, and an innerface 73 engaging the relief end surface 21 of the fastener relief 19 onpilot body portion 15. Mounting screw 50 constitutes a single mountingscrew system, configured for at least partial reception in andengagement with any one of the three fastener reliefs 19 in the bodyportion 15 of pilot 10, which provides the sole support for mounting thebody portion 15 of pilot 10 in the die member 3,4, with a compactprofile and footprint that facilitates ease of die design, operation andmaintenance. The single mounting screw attachment of pilot 10 to diemember 3 also provides quick and easy installation and removal. As willbe appreciated by those skilled in the art, pilot assembly 1 can be usedeither with or without lock washer 71.

Pilot 10 is assembled by inserting four ejector pins 42 into theassociated ejector pin holes 44 in the body portion 15 of pilot 10 withthe enlarged circular outer ends or heads 44 oriented away from thestock strip 5. The spring member 35 is then inserted over the springretainer rod portion of pilot 10, and into the spring groove 32, suchthat the outer end 37 of the spring member 35 abuts the inner ends 44 ofthe ejector pins 42. Spring member 35 is then compressed to a pre-tensedstate, which permits insertion of the retainer ring 47 into the retainerring groove 33 at the inner end 30 of spring retainer rod portion 28,which contains the compressed spring member 35, and completes theassembly, such that spring member 35 biases each of the ejector pins 42outwardly through the apertures 22 in the closed end 16 of body portion15 to a normally fully extended position. The threaded outer end ofinstallation tool 66 is threadedly engaged in the threaded aperture 65in pilot body portion 15 and serves to guide the pilot 10 into pilothole 80 in the correct orientation, as discussed in greater detailbelow.

With reference to FIGS. 27-31, the assembled pilot assembly 1 is quicklyand easily installed in the illustrated upper die pad 3 in the followingmanner. The upper die pad 3 shown in FIGS. 27-31 is illustrated with thenormally lower mounting face 8 oriented upwardly in a non-runningcondition, so as to better visualize the various pilot mountingapertures. However, as is apparent to those skilled in the art, pilot 10is typically mounted in the lower mounting face of an upper pressurepad, or similar die component, and runs or operates in the orientationshown in FIGS. 1, 9 and 24-26. Initially, a non-threaded pilot aperture80 is formed in the lower or mounting face 8, of the upper die member 3using simple machining techniques and no special tooling, and is shapedto closely receive and retain the body portion 15 of the pilot 10therein. The illustrated pilot aperture 80 has a stepped construction,with a larger diameter aperture 81 disposed closest to the stock strip 5and lower die mounting surface 8, and a smaller diameter aperture 82disposed furthest away from the stock strip 5 and lower die mountingsurface 8, with an annular lip or collar 83 formed therebetween. Theouter sidewall 18 of the body portion 15 of pilot 10 fits closely withinthe larger aperture 81 of the pilot hole 80, and the inner end 17 of thebody portion 15 of pilot 10 engages collar 83 to axially locate pilot 10within pilot hole 80. The spring retainer rod portion 28 of pilot 10,along with spring member 35 and retainer ring 47, are positioned in thesmaller aperture 82 of the pilot hole 80. A single threaded mountingscrew aperture 85 is formed in the lower or mounting face 8 of diemember 3 at a location spaced laterally apart from the pilot hole 80 apredetermined distance, and is shaped to closely receive therein theshank portion 53 of mounting screw 50 and the lock washer 71. It isnoteworthy that screw aperture 85 can be located at several differentpositions on the mounting face 8 of die member 3 to avoid interferencewith other die components mounted thereon, so long as it can be alignedwith one of the three fastener reliefs 19 in the body portion 15 ofpilot 10, as shown in FIGS. 3, 3A and 29-31. A pocket 86 having agenerally U-shaped plan configuration extends between and connects thethreaded screw hole 85 and the larger pilot aperture 80 along the lowermounting face 8 of the upper pressure pad 3, and is sized to receive aportion of mounting screw 50 therein. As will be appreciated by thoseskilled in the art, assembled pilot 10 can also be installed in an upperpressure pad or other die component machined as outlined below, with thepressure pad 3 and/or die member oriented in the run condition shown inFIGS. 1 and 19.

The assembled pilot 10 is aligned with and inserted into the pilot hole80 in die member 3 in the manner illustrated in FIGS. 29-31. The bodyportion 15 of pilot 10 is rotated in pilot hole 80, so that one of threefastener reliefs 19 in the body portion 15 of pilot 10 is laterallyaligned with the threaded screw aperture 85 in the mounting face 8 ofdie member 3, as shown in FIG. 30. Mounting screw 50, with lock washer31 installed on the shank portion 53 of mounting screw 50, is theninserted into the threaded retainer aperture 85 in upper die pad member3, as shown in FIGS. 30 and 31. The tightening of mounting screw 50 inthe mounting screw aperture 85 in the die member 3 abuttingly engages atleast a portion of the inner face 73 of the lock washer 71 on mountingscrew 50 securely against the relief end surface 21 of the alignedfastener relief 19 in the body portion 15 of pilot 10, as shown in FIG.31, to securely, yet detachably mount the pilot assembly 1 on the diemember 3 in a manner which causes the ejector pins 42 to automaticallyreciprocate between the retracted and extended positions relative to thebody portion 15 of the pilot 10 during operation of the metal formingdie to ensure that the stock strip 5 is consistently and fully strippedaway from the pilot 10. As will be appreciated by those skilled in theart, under special and/or abnormal conditions, multiple mounting screws50 may be used to secure pilot 10 in die member 3. Essentially, the fullcylindrical portions of the body portion 15 of pilot 10, when closelyreceived in the pilot hole 80 of die pressure pad 3, precisely locateand support the pilot 10 in the die workstation 102, and the singlemounting screw 50 securely, yet detachably retains the pilot assembly 1in pilot hole 80.

The pilot 10 and related pilot assembly 1 may be readily removed fromdie member 3 by simply reversing the sequence of the installation stepsdescribed above. In the illustrated example, a puller tool 66 (FIG. 31)is provided to facilitate safe removal and handling of the pilot 10.More specifically, puller tool 66 has a threaded outer end 66 a that isthreadedly engaged in the threaded aperture 65 in pilot body portion 15,and a weighted sliding handle 66 b which is manually shifted outwardlyalong the rod shaped body of puller tool 66 to impact an enlarged head66 c, thereby imparting sufficient outwardly directed forces to easilyextract pilot 10 from the pilot hole 80 in die member 3. Alternatively,pilot 10 can be removed from die member 3 by tapping it out of pilothole 80 with a punch and hammer applied from the outer end of pilot 10.

FIGS. 24-26 illustrate the operation of the pilot assembly 1, whereinFIG. 24 illustrates the upper die member 3 with pilot 10 mounted thereinconverging against the stock strip 5 that is supported on the uppersurface 9 of the lower die member 4. In this position, the ejector pins42 are fully extended, and just start to abut against the upper surfaceof the stock strip 5. The outer portion 26 of the point portion 24 ofpilot 10 is received through the most closely aligned one of the pilotholes 6 in stock strip 5 and into the female pilot portion 90 in thebottom or lower die member 4, but the collar portion of pilot 10 is not.Next, the upper die member 3 converges or closes completely against thestock strip 5 and lower die member 4 supporting the same in the mannerillustrated in FIG. 25, such that the abutting contact between the outerends 43 of the ejector pins 42 and the upper surface of the stock strip5 overcomes the biasing force of pre-tensed spring member 35 on ejectorpins 42, further compresses spring member 35, and shifts or retracts theejector pins 42 back toward the interior of the body portion 15 of pilot10. As shown in FIG. 25, the collar portion 25 of the point portion 24of pilot 10 is now fully received in the female pilot portion 90 ofbottom die member 4. The metal forming operation at the associated diework station 12 is then completed with the pilot assembly 1 in theposition shown in FIG. 25, such that the stock strip 5 is preciselylocated and securely held in place during formation and furtherprocessing of stock strip 5. As the upper die member 3 diverges or movesaway from the stock strip 5 and lower die member 4, the resilient forcesgenerated by spring member 35 urge the ejector pins 42 back outwardlytoward the stock strip 5 and separate or strip the stock strip 5 fromthe pilot, even when it sticks on the outer surfaces of the nose portionof the pilot 10, such that the stock strip 5 can then be quickly shiftedlongitudinally to the next work station 12 for further processing.

It is also possible to mount pilot assembly 1 in an associated diemember by forming a blind hole pocket in the die member, instead of thethrough hole mounting aperture 80, as best shown in FIGS. 27-31. Theassembled pilot 10 is inserted into the blind hole pocket and retainedtherein using a single fastener in the manner disclosed in detail inApplicant's related U.S. application Ser. No. 13/545,226, filed Jul. 10,2012, entitled MODULAR PILOT ASSEMBLY WITH SELF-CONTAINED STRIPPER ANDMETHOD FOR METAL FORMING DIES, which is incorporated herein byreference. With this alternate mounting arrangement, the retainer groove33 on pilot 10 and retainer ring 47 can be eliminated by using the blindbottom surface of the pocket to retain an inner end of the spring member35, as will be appreciated by those skilled in the art.

As will be appreciated by those skilled in the art, pilot assembly 1 canbe provided in a wide variety of sizes to accommodate many differentmetal forming die applications. The all-in-one, modular construction ofpilot assembly 1 not only provides a self-contained stock stripper thatuses only one spring, but can be quickly and easily installed directlyin a die member using simple machining techniques, and a single mountingscrew.

Pilot assembly 1 has an uncomplicated construction with relatively fewcomponents and is therefore quite durable and economical to manufacture.The single mounting screw attachment of the pilot assembly to anassociated die member provides quick and easy installation and removal.Pilot assembly 1 has a self-contained stripper which positivelyseparates the stock strip from the pilot during operation of the metalforming die, and provides a very compact, low profile shape that can beused at various locations and orientations on the various die members.The installation of the pilot assembly 1 can be achieved with simplemachining, so as to reduce installation time and cost.

In the foregoing description, it will be readily appreciated by thoseskilled in the art that modifications may be made to the inventionwithout departing from the concepts disclosed herein. Such modificationsare to be considered as included in the following claims, unless theseclaims by their language expressly state otherwise.

The invention claimed is:
 1. In a multi-station progressive metalforming die having at least two mutually converging and diverging diemembers between which an elongate stock strip is shifted longitudinallyto form parts from the stock strip, the improvement of a modular pilotassembly with self-contained stripper, comprising: a pilot operablysupported on one of said die members and having an outer end orientedtoward the stock strip, an oppositely disposed inner end oriented awayfrom the stock strip, and a medial portion disposed axially between saidouter and inner ends, and including: a body portion having an outer endoriented toward the stock strip, an inner end oriented away from thestock strip, and an outer wall with a least one fastener relief therein,as well as at least one axially extending ejector pin aperture whichopens through said outer end and into said inner end; a point portiondisposed at said outer end of said pilot shaped for close reception in apilot hole in the stock strip, and an outer portion configured to engagethe pilot hole in the stock strip and guide the same to a predeterminedposition in an associated die forming station; a spring retainer portiondisposed at said inner end of said pilot, having an outer end orientedtoward the stock strip, an inner end oriented away from the stock strip,and an annularly shaped spring groove adjacent said outer end of saidspring retainer portion; a spring member that is received onto and oversaid spring retainer portion of said pilot, an outer end oriented towardthe stock strip and received in said spring groove, and an oppositeinner end oriented away from the stock strip and positioned adjacent tosaid retainer groove in said spring retainer portion; at least one rigidejector pin slidingly received and retained in said ejector pin aperturein said body portion, having an outer end that protrudes outwardly fromsaid outer end of said body portion when urged to an extended conditionto contact the stock strip and strip the same away from said pilot, andretracts toward the body portion when urged to a retracted position, andan inner end that operably engages said outer end of said spring memberand is thereby biased outwardly by said spring member toward saidextended condition; a retainer ring detachably received on said springretainer portion and engaging said inner end of said spring member in apre-tensed condition to bias said ejector pin toward said extendedcondition; and a mounting fastener having an enlarged head portion thatis at least partially, closely received in said fastener relief in saidbody portion, and a shank portion anchored in said one die member tosecurely mount said pilot assembly on said one die member in a mannerwhich causes said ejector pin to automatically reciprocate between saidretracted and extended positions relative to said body portion of saidpilot during operation of said metal forming die to ensure that thestock strip is consistently stripped away from said pilot.
 2. A metalforming die as set forth in claim 1, including: a retainer groovedisposed adjacent said inner end of said spring retainer portion.
 3. Ametal forming die as set forth in claim 2, wherein: said retainer ringis detachably received in said retainer groove.
 4. A metal forming dieas set forth in claim 1, wherein: said pilot has a one-piececonstruction formed from a solid bar of rigid material.
 5. A metalforming die as set forth in claim 4, wherein: said body portion of saidpilot includes a plurality of said ejector pin apertures having asubstantially identical configuration and arranged in a spaced apartpattern through said body portion to ensure effective stripping of thestock strip from said pilot; and including a plurality of said ejectorpins having a substantially identical configuration and slidinglyreceived and retained in said ejector pin apertures in said body portionof said pilot.
 6. A metal forming die as set forth in claim 5, wherein:said body portion of said pilot includes a plurality of said fastenerreliefs having a substantially identical configuration and arranged in aspaced apart pattern around said outer wall of said body portion tofacilitate mounting said pilot assembly at various locations andorientations on said one die member.
 7. A metal forming die as set forthin claim 1, wherein: said mounting fastener is a threaded screw.
 8. Ametal forming die as set forth in claim 1, wherein: said body portionhaving a generally cylindrical shape.
 9. A modular pilot assembly withself-contained stripper for multi-station progressive metal forming dieshaving at least two mutually converging and diverging die membersbetween which an elongate stock strip is shifted longitudinally to formparts from the stock strip, comprising: a pilot configured for operablesupport on an associated die member, and having an outer end orientedtoward the stock strip, an oppositely disposed inner end oriented awayfrom the stock strip, and a medial portion disposed axially between saidouter and inner ends, and including: a body portion having an outer endoriented toward the stock strip, an inner end oriented away from thestock strip, and an outer sidewall with at least one fastener relieftherein, as well as at least one axially extending ejector pin aperturewhich opens through said outer end and into said inner end; a pointportion disposed at said end of said pilot shaped for close reception ina pilot hole in the stock strip, and an outer portion configured toengage the pilot hole in the stock strip and guide the same to apredetermined position in an associated die forming station; a springretainer portion disposed at said inner end of said pilot, having anouter end oriented toward the stock strip, an inner end oriented awayfrom the stock strip, and an annularly shaped spring groove adjacentsaid outer end of said spring retainer portion; a spring member receivedon and over said spring retainer portion of said pilot, an outer endoriented toward the stock strip and received in said spring groove, andan opposite inner end oriented away from the stock strip and positionedadjacent to said retainer groove in said spring retainer portion; atleast one rigid ejector pin slidingly received and retained in saidejector pin aperture in said body portion, having an outer end thatprotrudes outwardly from said outer end of said body portion when urgedto an extended condition to abut the stock strip and strip the same awayfrom said pilot, and retracts toward the body portion when urged to aretracted position, and an inner end that operably engages said outerend of said spring member and is thereby biased outwardly by said springmember toward said extended condition; a retainer ring detachablyreceived on said spring retainer portion and engaging said inner end ofsaid spring member in a pre-tensed condition to bias said ejector pintoward said extended condition; and a mounting fastener having anenlarged head portion that is at least partially, closely received insaid fastener relief in said body portion, and a shank portionconfigured for anchoring in an associated die member to securely mountsaid pilot assembly on the associated die member in a manner whichcauses said ejector pin to automatically reciprocate between saidretracted and extended positions relative to said body portion of saidpilot during operation of the metal forming die to ensure that the stockstrip is consistently stripped away from said pilot.
 10. A modular pilotassembly as set forth in claim 9, including: a retainer groove disposedadjacent said inner end of said spring retainer portion.
 11. A modularpilot assembly as set forth in claim 10, wherein: said retainer ring isdetachably received in said retainer groove.
 12. A modular pilotassembly as set forth in claim 9, wherein: said pilot has a one-piececonstruction formed from a solid bar of rigid material.
 13. A modularpilot assembly die as set forth in claim 12, wherein: said body portionof said pilot includes a plurality of said ejector pin apertures havinga substantially identical configuration and arranged in a spaced apartpattern through said body portion to ensure effective stripping of thestock strip from said pilot; and including a plurality of said ejectorpins having a substantially identical configuration and slidinglyreceived and retained in said ejector pin apertures in said body portionof said pilot.
 14. A modular pilot assembly as set forth in claim 13,wherein: said body portion of said pilot includes a plurality of saidfastener reliefs having a substantially identical configuration andarranged in a spaced apart pattern around said outer wall of said bodyportion to facilitate mounting said pilot assembly at various locationsand orientations on said one die member.
 15. A modular pilot assembly asset forth in claim 9, wherein: said mounting fastener is a threadedscrew.
 16. A modular pilot assembly as set forth in claim 9, wherein:said body portion and said spring retainer portion having a generallycylindrical shape.
 17. In a method for making a multi-stationprogressive metal forming die having at least two mutually convergingand diverging die members between which an elongate stock strip isshifted longitudinally to form parts from the stock strip, with theimprovement of at least one modular pilot with self-contained stripperfor precisely locating the stock strip in the die stations, comprising:forming a body portion with an outer end oriented toward the stockstrip, an inner end oriented away from the stock strip, and an outerwall with at least one fastener relief therein, as well as at least oneaxially extending ejector pin aperture which opens through the outer endand into said inner end; forming a point portion on an outer end of thepilot with a portion disposed adjacent the outer end of the body portionshaped for close reception in a pilot hole in the stock strip, and anouter portion configured to engage the pilot hole in the stock strip andguide the same to a predetermined position in an associated die formingstation; forming a spring retainer portion on an inner end of the pilotwith an outer end oriented toward the stock strip, an inner end orientedaway from the stock strip, and an annularly shaped spring grooveadjacent the outer end of the spring retainer portion; forming at leastone rigid ejector pin with an inner end, and an outer end configured toprotrude outwardly from the outer end of the body portion when urged toan extended position to contact the stock strip, and to retract towardthe body portion when urged to a retracted position; inserting theejector pin into the ejector pin aperture in the body portion of thepilot, such that the ejector pin is slidingly received and retained inthe ejector pin aperture for longitudinal reciprocation therein betweenthe extended and retracted positions; selecting a spring member with agenerally hollow interior, an outer end oriented toward the stock strip,and an opposite inner end oriented away from the stock strip;positioning the hollow interior of the spring member onto and over thespring retainer portion of the pilot, with the outer end of the springmember received in the spring groove and abutting the inner end of theejector pin, and the inner end of the spring member positioned adjacentto the retainer groove in the spring retainer portion; shifting theinner end of the spring member outwardly along the spring retainerportion of the pilot to compress the spring member to a pre-tensedcondition, such that the outer end of the spring member operably engagesthe inner end of the ejector pin and biases the ejector pin to theextended position; installing a retainer ring on the spring retainerportion with the spring member in the pre-tensed condition, such thatthe retainer ring abuttingly engages the inner end of the spring memberand retains the spring member in the pre-tensed condition on the springretainer portion of the pilot, thereby resiliently urging the ejectorpin to the normally extended position; forming a non-threaded pilotaperture in a mounting face of one of the die members with a shape toclosely receive and retain the body portion of the pilot therein;forming a threaded mounting fastener aperture in the mounting face ofthe one die member at a location spaced laterally apart from the pilotaperture a predetermined distance; inserting the pilot into the pilotaperture in the one die member with the outer sidewall of the bodyportion of the pilot closely received therein, and with the fastenerrelief in the body portion of the pilot facing and aligned with themounting fastener aperture in the one die member, so as to accuratelylocate the pilot on the one die member; selecting a mounting fastenerhaving an enlarged head portion sized for at least a portion thereof tobe closely received in the fastener relief in said body portion of thepilot, and a threaded shank portion; inserting the threaded shankportion of the mounting fastener axially into the mounting fasteneraperture in the mounting face of the one die member, such that at leasta portion of the enlarged head portion of the mounting fastener isclosely received in the fastener relief and adjacent a portion of thesidewall of the fastener relief on the body portion of the pilot; andtightening the mounting fastener in the mounting fastener aperture inthe one die member, thereby abuttingly engaging at least a portion ofthe mounting fastener head portion securely against a portion of thefastener relief in the body portion of the pilot to securely, yetdetachably mount the pilot assembly on the one die member in a mannerwhich causes the ejector pin to automatically reciprocate between theretracted and extended positions relative to the body portion of thepilot during operation of the metal forming die to ensure that the stockstrip is consistently stripped away from the pilot.
 18. A method as setforth in claim 17, wherein: said retainer forming step includes forminga retainer groove disposed adjacent the inner end of the spring retainerportion.
 19. A method as set forth in claim 18, wherein: said retainerring installation step includes installing the retainer ring in theretainer groove.
 20. A method as set forth in claim 17, wherein: saidmounting fastener selecting step comprises selecting a threaded screw.